Complete Manufacturing Process of Liquid Cooling Plate (Battery Cooling Plate)

Stamped Brazed Liquid Cooling Plate (Mainstream, Soft-Pack/Square Battery)

Aluminum Plate Blanking: Uncoiling aluminum coils, CNC shearing, cutting upper and lower substrates and flow channel plates; deburring, cleaning and degreasing.

Stamping Forming (Critical): Hydraulic/servo stamping, stamping fluid flow channel grooves (serpentine, S-shaped, multi-channel) into the middle plate; checking flow channel depth, rounded corners, no cracks, and wrinkles.

Machining Pre-treatment:

Milling: Edge sealing allowance, inlet/outlet connector base positioning surface

Punching: Coolant inlet/outlet, positioning holes, mounting holes

Deburring, chamfering

Surface Cleaning: Alkali washing → rinsing → passivation → drying; removing stamping oil and aluminum powder to ensure brazing bond strength.

Brazing Material Laying: Two substrate layers + middle flow channel plate stacked; placing aluminum-silicon brazing foil/brazing paste around the flow channel, precisely aligning and clamping with tooling fixtures to prevent misalignment.

Vacuum Brazing (Core Process) The vacuum brazing furnace heats the material to 580-610℃, melting and wetting the interface of the plate. After cooling, a complete metallurgical bond is achieved.

Control: Vacuum degree, heating rate, and holding time are crucial to prevent incomplete welds, flow channel blockage, and bulging.

Post-Welding Machining Milling excess edge banding on all four sides; machining weld bevels for the joints; machining mounting holes.

Joint Welding Argon arc welding/laser welding of aluminum joints/nozzles to the liquid cooling plate body; welding of inlet and outlet interfaces.

Leak Detection Process (Mandatory)

① Hydrostatic Testing: Holding pressure at 1.5-2.0MPa to check for leaks.

② Helium Detection (High Precision): Vacuum helium mass spectrometry leak detection; leak rate meets standards; non-conforming parts are marked for rework/scrapping.

Cleaning and Drying Internal rinsing to remove aluminum shavings and brazing residue; compressed air drying of the internal flow channels to remove water accumulation.

Surface Treatment

Optional: Passivation, anti-corrosion coating, conductive oxidation;

Full visual inspection: Deformation, dents, cracks.

Final Inspection & Packaging

Dimensional inspection, flow channel testing; Labeling, sealed packaging.